ATH KN-6 Installation And Operation Instructions Manual

Kn series cast iron condensing boilers

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Control manual (108 pages)

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Installation and Operation

Instructions

Cast Iron Condensing Boilers

Models K N-6, KN-10, KN-16,

KN-20, KN-26 and KN- 30

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Summary of Contents for ATH KN-6

Page 1: Installation And Operation
KN-W-IOM2-0814 42-9554 Boiler Manual Installation and Operation Instructions Cast Iron Condensing Boilers Models K N-6, KN-10, KN-16, KN-20, KN-26 and KN- 30 Also read and follow: KN Control Manual MEA #444-05-E MASS Plumbers #G1-06-04-28 Th is manual is intended only for use by a qualifi ed heating installer/technician. Read and follow this manual, all supplements and related instructional information provided with the boiler.
Page 2: Table Of Contents
Cast Iron Condensing Boilers – Installation Manual CONTENTS If the information in this manual is not followed exactly, a ﬁ re or explosion may result causing Before Your Start..........page 2 property, personal injury or loss of life. Ratings & Capacities .......... page 3 Location ..............
Page 3: Ratings & Capacities
Cast Iron Condensing Boilers – Installation Manual The owner should maintain a record of all service work The KN may be installed directly on performed with the date and a description of the work combustible ﬂ ooring, but never on carpeting. done.
Page 4 Cast Iron Condensing Boilers – Installation Manual Buildings will require the installation of a fresh air duct Where communicating with the outdoors through hori- or other means of providing make-up air if the intake zontal ducts, each opening shall have a minimum free air option isn't used.
Page 5: General Venting Guidelines
Cast Iron Condensing Boilers – Installation Manual All joints in metal intake air systems must be A barometric damper or blast gate as secured using corrosion resistant fasteners required, must be installed if a Category II and sealed using a suitable Silicone caulk. If vertical vent system produces a negative PVC or CPVC is used, the joints must be draft in excess of 0.15 in, 3.8 mm WC at the...
Page 6 Cast Iron Condensing Boilers – Installation Manual DIRECT VENT Use (Table 4) for the maximum Category (IV) equivalent vent length and the equivalent POSITIVE PRESSURE, CATEGORY IV length per fitting. Table 4 - “Category IV In this conﬁ guration the boiler blower is used to push Equivalent Length per Fitting”...
Page 7 Cast Iron Condensing Boilers – Installation Manual Avoid terminal locations likely to be affected by winds, The top of a vertical vent system must extend at least snowdrifts, people and pets. Protect building materials ft, 1.8 m above the roof surface that it passes and vegetation from degradation caused by the ﬂ...
Page 8 2. Install an approved vent cap at each vent termination. Consult factory when venting more than the 3. Dimensions: following number of KN boilers: B = breeching length KN-6/10/16 (5) boilers maximum C = chimney height KN-20/26/30 (4) boilers maximum D = breeching diameter F = riser diameter...
Page 9 Cast Iron Condensing Boilers – Installation Manual Figure 2 - Horizontal Air Intake and Venting for a Single Direct Vent System Figure 3 - Horizontal Air Intake and Venting for Multiple Direct Vent Systems...
Page 10 Cast Iron Condensing Boilers – Installation Manual Figure 4 - Vertical Air Intake and Venting for Direct Vent System Figure 5 - Combination Direct Vent Systems...
Page 11 Cast Iron Condensing Boilers – Installation Manual SIDE WALL VENT The air for combustion is taken from the space in which the unit is installed. The applicable instructions under POSITIVE PRESSURE, CATEGORY IV the COMBUSTION AIR & VENTILATION SECTION In this conﬁ guration the boiler blower is used to push the must be followed! The vent guidelines under the ﬂ...
Page 12 Cast Iron Condensing Boilers – Installation Manual VERTICAL VENT (Optional) The vent system should be sloped up toward the chimney at a minimum rate of 1/4 in/ft, 2 cm/m. NEGATIVE PRESSURE - CATEGORY II The KN is listed as a Category II appliance when vented Always provide a minimum clearance of 6 in, 152 mm vertically into a listed metal AL294C S.S.
Page 13: Common Vent Systems
Cast Iron Condensing Boilers – Installation Manual EXISTING COMMON VENT SYSTEMS Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre If an existing boiler is removed from a common venting l'espace où...
Page 14: General Piping Requirements
Cast Iron Condensing Boilers – Installation Manual GENERAL PIPING REQUIREMENTS Table 6 Water Improper piping of this boiler will void the Flow Rates *ΔT Across Model manufacturer’s warranty and can cause boiler (GPM) Heat Exchanger Size failure resulting in flooding and extensive Min.
Page 15: Heating System Piping
Cast Iron Condensing Boilers – Installation Manual HEATING SYSTEM PIPING Water Treatment This boiler was designed to operate in a closed loop heating system. System ﬁ ll water must not contain more General Piping Requirements than 500 ppm of total dissolved solids and no greater All heating system piping must be installed by a qualiﬁ...
Page 16 Cast Iron Condensing Boilers – Installation Manual Primary/Secondary Piping When a boiler is connected to a heating coil that may Although acceptable, the system is not as cost effective be exposed to refrigerated air from an air handling as reverse return piping. Figure 12 shows a typical device, the piping system must be equipped with ﬂ...
Page 17 Cast Iron Condensing Boilers – Installation Manual Figure 11 - Typical Multiple Boiler Reverse Return Piping (RECOMMENDED) (Careful consideration as to minimum boiler and system water ﬂ ow rates must be taken. Please consult our local manufactures representative for assistance.) Motorized Valve HIOM-11 REV .5...
Page 18: Domestic Water Supply Piping
Cast Iron Condensing Boilers – Installation Manual DOMESTIC WATER SUPPLY PIPING The storage tank must be located as close to the boiler as possible to prevent excessive head loss which will reduce ﬂ ow. Proper controls must be used to prevent water supplied for domestic use from Expansion Tank exceeding 130°F, 54°C or a scald injury will...
Page 19 Cast Iron Condensing Boilers – Installation Manual Figure 15 - Typical Multiple Boiler with Indirect Storage Tank Piping NOTES: 1. When using intermittent pump and pump delay, locate HeatNet sensor with well in lower 1/3 of tank. Install sensor with heat sensing compound. 2.
Page 20: Condensate Piping
Cast Iron Condensing Boilers – Installation Manual CONDENSATE PIPING GAS SUPPLY PIPING The condensate trap provided with the boiler must be attached to the bottom pan and piped to a suitable ﬂ oor Check the boiler rating plate to make sure that drain (consult local code) or condensate pump.
Page 21: Electrical Wiring
Canada. Install a separate 120 volt 15 amp circuit for from the boiler main gas valve. All boilers are each KN-6 or KN-10 boiler. Install a separate 230 volt calibrated and factory test fired at 1Ø with neutral 20 amp circuit for each KN-16, KN-20 (7 in ±...
Page 22: Boiler Operation
Cast Iron Condensing Boilers – Installation Manual BOILER OPERATION The system should be checked and bled after three days of operation. Before proceeding read and fully understand OPERATING INSTRUCTIONS the instructions contained in this manual. Do not attempt to operate this boiler if it has not FOR YOUR SAFETY READ BEFORE OPERATING.
Page 23 Cast Iron Condensing Boilers – Installation Manual Operating Instructions 13. Slide the HeatNet controls low ﬁ re switch (on the 1. STOP! Read the safety information above. If, at HeatNet control board) to the low ﬁ re position. any time, the appliance will not operate properly, follow the instructions “TO TURN OFF GAS TO 14.
Page 24 Cast Iron Condensing Boilers – Installation Manual 23. Reset the Honeywell 7800. The boiler will start and Instructions De Mise En Marche will run at minimum input rate. 1. ARRÊTEZ! Lisez les instructions de sécurité sur la portion supérieure de cette étiquette. 24.
Page 25: Sequence Of Operation
Cast Iron Condensing Boilers – Installation Manual SEQUENCE OF OPERATION Main Run %Input 1. The main gas valve opens. NO DEMAND 2. The ignition transformer is de-energized. Standby 1. The boiler is idle with no interlocks in the fault 3. The pilot solenoid valve closes. condition.
Page 26 **Located on outlet ﬂ ange of gas valve. (Figure 17, page 21) Due to job conditions, deviation from speciﬁ ed may be required – allow ± (0.2)% range adjustment. Table 12 - Pressure Signal (P) - (Nat. Gas) KN-6 KN-10 KN-16...
Page 27: Ignition Troubleshooting
Cast Iron Condensing Boilers – Installation Manual KN Series "Heat Net Control" Troubleshooting (Firing the KN Boiler) Variable Frequency KN Control Functions Ignition Contrrol Hand Shake Drive Ignition Sequence (Honeywell S7800) INPUTS: DISPLAY: 1. MODBUS STANDBY CALL FOR 2. AA HEAT? 3.Heat Demand 4.
Page 28: Checking & Adjustment
With the unit powered generate a call for heat. The boiler KN-10 " will start to go through it start up sequence. During the KN-6 " ignition/pilot sequence observe the lights on the Honeywell 7895C. The pilot light should come on but not Pilot Adjustment the ﬂ...
Page 29: Diagnostics
Cast Iron Condensing Boilers – Installation Manual Ignition Safety DIAGNOSTICS To test the ignition safety shutoff device, close the The KN has a display that indicates the sequence of manual shutoff valve 1 (Figure 17) in the gas supply line. operation, Figure 18.
Page 30: Maintenance
Cast Iron Condensing Boilers – Installation Manual MAINTENANCE Controls Use the BOILER OPERATION and CHECKING AND ADJUSTMENT sections of this manual for reference. Disconnect electrical power and close the 1. Check the operating controls for proper operation. manual gas shut off valve before performing maintenance or severe personal injury may 2.
Page 31: Pressure Switches
Cast Iron Condensing Boilers – Installation Manual Figure 22 - KN-6, 10, 16, 20, 26 and 30 Pressure Switches...
Page 32: Wiring
Cast Iron Condensing Boilers – Installation Manual Figure 23 - ATH Field Wiring to HeatNet Board 3.0 (KN-6, KN-10, KN-16, KN-20, KN-26 and KN-30)
Page 33: Start-Up
Cast Iron Condensing Boilers – Installation Manual START-UP REPORT DATE: JOB NAME: TECHNICIAN: LOCATION: COMPANY: MODEL: PHONE NUMBER: SERIAL #: PRE-STA T T RTUP CHECK LIST NO VISIBLE DAMAGE TO UNIT INLET AIR FILTER INSTALLED AND CLEAN PIPING PROPERLY CONNECTED PROPER SERVICE CLEARANCES PROVIDED BOILER CIRCULATOR WIRED PUMP RUNNING, HEAT EXCHANGER FULL...
Page 34 Cast Iron Condensing Boilers – Installation Manual CO M BUSTI O N ANALYSIS MINIMUM FIR I NG RATE 1 00% FIR IN G RATE GAS INLET PRESSURE (WC) INCHES WC I NCHES WC CO ( PPM ) PP M NET S TA C K TEMPERAT U R E AIR BOX DIFFERENTIAL (DELTA P - WC) INCHES WC INCHES WC...
Page 35: Repair Parts
Cast Iron Condensing Boilers – Installation Manual Figure 24 - KN-6, 10, 16, 20, 26 and 30 AIOM-95 REV.- F SEE VIEW "A" AIOM-95 REV.-F AIOM-95 REV.- F...
Page 36 Cast Iron Condensing Boilers – Installation Manual Figure 25 - KN-6, 10, 16, 20, 26 and 30 SEE VIEW "C" AIOM-95 REV.- F "VIEW E" SEE VIEW "B"...
Page 37 Cast Iron Condensing Boilers – Installation Manual Figure 26 - Gas Train/Drain Pan KN-6, 10, 16, 20, 26, 30 High Fire CO Adjustment Screw - Clockwise = Increase Counterclockwise = Decrease "VIEW B" AIOM-95 REV.- F "VIEW C" AIOM-95 REV.- F...
Page 38 Cast Iron Condensing Boilers – Installation Manual Figure 27 - Control Panel...
Page 39 Cast Iron Condensing Boilers – Installation Manual SERVICE AND REPLACEMENT PARTS LIST - KN-6, KN-10 WHIRLWIND, KN-16, KN-20, KN-26 and KN-30 Model Size with Item Quantities Below Item Description Part # KN-6 KN-10 KN-16 KN-20 KN-26 KN-30 Supply Sensor 02-4284...
Page 40 Cast Iron Condensing Boilers – Installation Manual SERVICE AND REPLACEMENT PARTS LIST - KN-6, KN-10 WHIRLWIND, KN-16, KN-20, KN-26 and KN-30 Model Size with Item Quantities Below Item Description Part # KN-6 KN-10 KN-16 KN-20 KN-26 KN-30 Burner Weldment 74-00231-006...
Page 41 Cast Iron Condensing Boilers – Installation Manual SERVICE AND REPLACEMENT PARTS LIST - KN-6, KN-10 WHIRLWIND, KN-16, KN-20, KN-26 and KN-30 Model Size with Item Quantities Below Item Description Part # KN-6 KN-10 KN-16 KN-20 KN-26 KN-30 Power Switch, Rocker...
Page 42: Installation Requirements
Cast Iron Condensing Boilers – Installation Manual MACODE-3 NOTICE! Commonwealth of Massachusetts Installation Requirements (a) For all side wall horizontally vented gas fueled In the Commonwealth of Massachusetts, the equipment installed in every dwelling, building or structure installation must be performed by a licensed used in whole or in part for residential purposes, including plumber or gas ﬁ...
Page 43: Warranty
Cast Iron Condensing Boilers – Installation Manual KN-Series Water Boiler Limited Warranty One-Year Warranty The “Manufacturer” warrants to the original owner at the original installation site that the KN-Series modulating water boiler (“Product”) will be free from defects in material and workmanship for one (1) year from the date of installation or eighteen (18) months from the date of shipment from the factory whichever comes ﬁ...
Page 44 IN UNITED STATES: 260 NORTH ELM ST. • WESTFIELD, MA 01085 • (413) 564-5515 • FAX (413) 568-9613 IN CANADA: 7555 TRANMERE DRIVE • MISSISSAUGA, ONT. L5S 1L4 • (905) 670-5888 • FAX (905) 670-5782 www.knseries.com...

This manual is also suitable for:

Kn-10 Kn-30 Kn-16 Kn-20 Kn-26